ECS Tuning Aluminum Intake Manifold With Fitting Kit - Wrinkle Black Finish - 2.0TSI

OVERVIEW

The ECS Tuning Fabricated Aluminum Intake Manifold for the VW/Audi 2.0T TSI engine provides even air flow distribution to all four cylinders while increasing throttle response due to its 53% larger plenum volume over the stock manifold. If you've upgraded to a larger turbo and you're looking to take your build to the next level, then the ECS Aluminum Intake Manifold is for you! This manifold is the perfect foundation for improved throttle response, balanced airflow and increased top end charge to maximize your engine's efficiency. 

The OEM plastic intake manifold suffers from cylinder imbalance by up to 10% between runners. The result is uneven cylinder filling within the outer runners and variations in air/fuel ratios which can create dangerous conditions! Our intake manifold equalizes this flow imbalance without sacrificing any efficiency, providing a flow balance deviating less than 1%. In addition, our manifold eliminates the problematic air divider drive units. We recorded an airflow increase of up to +8% CFM over the factory TSI manifold. 

Our Engineering Team at ECS Tuning sought out to make the best intake manifold available on the market. Rather than designing a cast manifold, they took a different approach. This meant engineering a billet and fabricated aluminum sheet design, featuring 5-Axis CNC machined aluminum mounting flanges and billet CNC intake runners. This design provides an optimal flow path and smooth transitions from the parabolic velocity stacks inside the plenum to the intake port shape. This allowed us to achieve the smoothest airpath possible which we favored over rough casting marks found from traditional cast designs. Our billet runners feature 1/8" NPT ports which are ready for nitrous or water/meth injection nozzles. NPT pipe plugs are included for those not running power adders/post cooling devices. The 5052 aluminum sheet plenum houses the billet velocity stacks, while increasing plenum volume by 53% over the factory manifold for increased throttle response and improved cylinder filling. 

Our ECS Intake Manifolds were designed, engineered, tested and quality inspected by our in-house engineering team in our Wadsworth, Ohio facility. All fabrication, TIG welding, machining and forming are done right here in the U.S.A. by expert fabricators using U.S.A. sourced materials! 

** CUSTOM TUNING AND SUPPORTNG MODIFICATIONS NOTE: **

Please read ALL of the information in the description below the INSTALLATION AND SUPPORT header prior to purchasing. Please note, bolting on our intake manifold by itself without further supporting modifications and ECU tuning will not result in more power with OEM sized turbochargers. We recommend our manifold to be used with a larger frame turbo, a more efficient intercooler, freer flowing exhaust and intake upgrades and custom ECU tuning to remove the intake runner check engine light, revise cold start maps and to maximize the benefits our manifold can create. Due to the removal of the front PCV port our intake manifold requires an Oil Can Can Kit without the front PCV port. 

PART DESIGN

Cylinder Head Flange:

• 5-Axis CNC machined from 6061 aluminum 

• Machined O-ring grooves secure the included individual Buna-N O-ring seals 

• 100% compatible with the OEM fuel rail, fuel rail bracket and injector wiring harness with no modifications or trimming required 

Intake Runners:

• 5-Axis CNC machined from 6061 aluminum to provide equal runner velocity and optimal interior surface finish

• Designed to provide optimal flow path and super smooth transitions between the plenum flange and head flange

• Secondary fueling/cooling/nitrous nozzle bosses are pre-machined atop each intake runner for direct port water/meth injection or nitrous nozzles 

  • Pipe plugs are included to block these off

Plenum Flange:

• 5-Axis CNC machined from 6061 aluminum

• Features parabolic velocity stacks which provide smooth airflow into each intake runner

Intake Plenum:

• Formed from 1/8" thick 5052 sheet aluminum 

• 53% larger plenum volume (2.47 Liters) promotes even air flow distribution to each runner while increasing throttle response and consistent cylinder filling

​Throttle Body Flange:

• CNC machined from 6061 aluminum​

• 70mm throttle body opening; features a radiused outlet for smooth airflow entry into the plenum

• Compatible with OEM and larger aftermarket throttle bodies (tested with OEM and Grams 70mm)

• Includes IAT sensor port and securing bolt 

• Incorporates 1/4" and 1/8" NPT vacuum ports in front and passenger side locations

  • Various pipe plugs and nipple fittings are included to accommodate various setups

Accessories:

• Compatible with OEM high pressure fuel line mounts, intake manifold support bracket, harness connectors and coolant hard lines
• Retains EVAP purge valve 
• Includes fuel rail stand-offs for OEM fuel rail compatibility 
• Eliminates OEM head flange and throttle body gaskets. Uses easily serviceable oil resistant Buna-N O-rings.

Final Assembly:

• Available in a raw machined finish or a wrinkle black powdercoat finish

• Fabricated, TIG welded, machined and formed in the U.S.A. by expert fabricators using U.S.A. sourced materials

• Tested to 0% leak down at 3 BAR for final quality 

KIT CONTENTS

• Intake Manifold Assembly - Raw Finish

• Fuel Rail Standoffs - QTY 5

• Intake Runner O-Rings - QTY 4

• Throttle Body O-Ring - QTY 1

• Various 1/8" NPT and 1/4" NPT Barbed Fittings and Pipe Plugs

• All new mounting hardware pack 

• 48" of 5/16" fuel hose

• Various unions, vacuum tee, vacuum cap and hose clamps 

• Fuel Injector Service Kit - QTY 4

PERFORMANCE FEATURES

• ​Our intake manifold provides even air flow distribution to all four cylinders while increasing throttle response due to its 53% larger plenum volume over the stock manifold.

  • Stock TSI plenum volume: 81 in.³ (1.33 Liters) 

  • ECS plenum volume: 151 in.³ (2.47 Liters)

• Provides the necessary foundation for supporting modifications such as a larger turbocharger, more efficient intercooler and freer flowing intake and exhaust upgrades, along with custom ECU tuning.

• Tested on our in-house Superflow Flow Bench we recorded +3 to +8% increase in CFM over the factory TSI manifold. Particularly runners #1 and #4 found +6 to +8% increase in airflow by up to 15 CFM. 

• The OEM plastic intake manifold suffers from cylinder imbalance by up to 10% between runners. This results in uneven cylinder filling within the outer runners causing undesirable variances in air/fuel ratios that can create dangerous conditions! Our intake manifold equalizes this flow imbalance without sacrificing any efficiency, providing a flow balance deviating less than 1%.

• Removes the air dividers for improved airflow

PRODUCT DEVELOPMENT

• Our ECS Fabricated Aluminum Intake Manifold was designed, engineered, tested and quality inspected by our Research and Development team in our Wadsworth, Ohio facility. After several design iterations, multiple prototypes and multiple vehicle test fitments we are proud to offer a truly remarkable intake manifold to the VW/Audi market! 

• We strive for the highest level of precision and quality through leading-edge product development technology including FARO laser scanning for reverse engineering and quality inspection, SolidWorks 3D CAD modeling, rapid prototyping utilizing our in-house 3D printer, and rigorous long term product testing.

• Performance data metrics were collected utilizing our in-house Superflow SF-750 Flowbench. 

INSTALLATION AND SUPPORT

​​Our intake manifold was designed to accommodate most OEM features and to provide a bolt-on installation. However, due to the nature of this product type it requires removal of several OEM parts, custom ECU tuning, supporting modifications and professional installation. 

Custom Tuning:

• Please check with your software tuner prior to purchasing. Our manifold removes the air guides. This WILL cause a check engine light and rough cold starts at cooler temperatures. Your software tuner will need the capability to remove the error code and remap your ECU for cold starts without the air guides. As noted above, bolting on our manifold will not create an impactful increase in power without custom software tuning to maximize the benefits of our part.

Supporting Modifications:

• In order to maximize the benefits of our intake manifold you must have a larger frame turbocharger, improved intercooler, freer flowing intake and exhaust upgrades and custom ECU software tuning. Our manifold has been tested and verified to operate on stock engines. This manifold works best when combined with other supporting modifications. 

Required Modifications:

• Due to the large plenum design and the removal of the front PCV port our intake manifold requires an Oil Can Can Kit without the front PCV port.

Professional Installation:

• We recommend advanced skills and experienced technicians to install our manifold. Our Installation PDF will guide an experienced technician through the procedure, but this install is not for the mechanically novice. Please read the entire installation PDF prior to installing this part.